Turned out not too bad. I know it doesn't match the factory piece as far as being recessed in the middle, plus we had to weld in the seam but it's going to be covered up with side panels similar to our TJ ones so luckily it won't be seen.

Cleaned up some spots in the floor
The passenger side rocker was pretty hammered as was the factory intenral brace so it all had to go...
made a new piece to tie into the brace...
Stay tuned as I start reconnecting the tub halves back together.

Thankfully we had a junk YJ sitting outside that we were able to cut the needed panels from. Once we quadrupled checked all our measurements we cut them down to the correct length and welded the PS one in place. For those who are curious we added 15 3/8" in front of the wheel well.

Someone told me that it's better to run large panels with rounded edges when possible to avoid corners which can crack. Made sense to me so thats what I did although they neglected to mention is how much of a PITA it is to trim the round panel for fitment.

Turned out not too bad. I know it doesn't match the factory piece as far as being recessed in the middle, plus we had to weld in the seam but it's going to be covered up with side panels similar to our TJ ones so luckily it won't be seen.

Hope this means you guys are going to offer some real cowl protection in the near future.

Next step was to start inserting the floor sections. We're going to do it in three pieces, an end piece in front of each wheel well then a center piece that will run between them.

End view of the end filler panel. I've got it upside down actually, the side that is pointed up will connect to where the factory floor board extends back several inches as well as to the center section piece. The front edge overlaps the factory floor while the rear runs under the wheel well. The side pointed down will connect to the side of the tub.

Here's the passenger side prepped.

Predrilled all the outer spot weld holes

Tacked in place

Fitting up the drivers side

Drivers side tacked in

Shot from underside

We should be able to get the center piece cut this week and hopefully installed next weekend.

Got the floor piece cut this week. It's got a 1" flange along the back for strength as well as along the sides so I can spot weld it to the side pieces. We also rolled some beads in it to add additional rigidity.

Bob suggested I use a scissor jack to raise the back up tightly against the floor, this also gave me something to push down against so I could make sure the two pieces were tight together when spot welding them.

Welded in place. I was concerned I might run into a wrinkle considering how much we cut everything apart but it all went together nicely.

What is your plan for the rear seat? I only ask because it seems like you would want to run the wheel wells further up and have more room in the rear. Although, it would also be a great spot to add some custom storage boxes with the extra space! As it sits, with the seat in the stock location to the foot well, you will have a lot of space on each side of the seat. Maybe you have room for a third seat from something like a Suburban? That could be set up to fold down, and use the quick release floor mounting. If you have room for that seat, you can bump seating up to 5! I happen to have a Suburban with this seat if you want some measurements.

Anyway, really slick work! I love seeing something done like this and not look hacked!